U.S. patent number 7,887,526 [Application Number 12/221,894] was granted by the patent office on 2011-02-15 for three-piece disposable undergarment.
This patent grant is currently assigned to Kimberly-Clark Worldwide, Inc.. Invention is credited to Jacqueline A. Gross, Russell E. Thorson, Paul T. Van Gompel.
United States Patent |
7,887,526 |
Van Gompel , et al. |
February 15, 2011 |
**Please see images for:
( Certificate of Correction ) ** |
Three-piece disposable undergarment
Abstract
A disposable undergarment includes a front body panel having a
pair of opposite first side edges, a first waist edge and a first
crotch edge spaced from said first waist edge. A rear body panel
has a pair of opposite second side edges, a second waist edge and a
second crotch edge spaced from said second waist edge. The crotch
edges of each of the front and rear body panel webs includes at
least one peak and at least one valley. Each of the front and rear
body panels have a minimum rise defined between the valley of each
of the respective front and rear body panels and the first and
second waist edges respectively. The valleys defining the minimum
rises form at least in part leg opening portions of the front and
rear body panels. The crotch edges of the front and rear body
panels are spaced apart and form a gap therebetween in a
non-overlapping relationship. A crotch member bridges the gap and
has opposite end portions connected to the front and rear body
panels respectively. The crotch member does not cover the valleys
defining the minimum rises of each of the front and rear body
panels.
Inventors: |
Van Gompel; Paul T.
(Hortonville, WI), Thorson; Russell E. (Appleton, WI),
Gross; Jacqueline A. (Neenah, WI) |
Assignee: |
Kimberly-Clark Worldwide, Inc.
(Neenah, WI)
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Family
ID: |
32030064 |
Appl.
No.: |
12/221,894 |
Filed: |
August 7, 2008 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20090048573 A1 |
Feb 19, 2009 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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11330422 |
Jan 11, 2006 |
7419562 |
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10452299 |
Jun 2, 2003 |
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10261805 |
Oct 1, 2002 |
6979380 |
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Current U.S.
Class: |
604/385.24;
604/385.28; 604/385.22; 604/385.29; 604/385.26; 604/385.25;
604/385.3 |
Current CPC
Class: |
A61F
13/15723 (20130101); A61F 13/15707 (20130101); A61F
13/15804 (20130101); A61F 13/15699 (20130101); Y10T
156/1051 (20150115); Y10T 156/1077 (20150115); Y10T
156/1095 (20150115); Y10T 156/1049 (20150115); Y10T
156/1093 (20150115); Y10T 156/1097 (20150115); Y10T
156/1066 (20150115); Y10T 156/1734 (20150115); Y10T
156/1087 (20150115); A61F 2013/49063 (20130101); Y10T
156/1067 (20150115); Y10T 156/133 (20150115); Y10T
156/1015 (20150115); Y10T 156/1008 (20150115); Y10T
156/1092 (20150115) |
Current International
Class: |
A61F
13/15 (20060101) |
Field of
Search: |
;604/385.201,385.24,385.25,385.26,385.28,385.29,385.22,385.3 |
References Cited
[Referenced By]
U.S. Patent Documents
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Other References
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Application No. PCT/US03/28637, dated Jan. 22, 2004, 9 pages. cited
by other .
International Search Report in corresponding International
Application No. PCT/US03/39405, dated Apr. 16, 2004, 6 pages. cited
by other .
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Application No. WIPO/US03/28245, dated Feb. 18, 2004, 7 pages.
cited by other .
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PCT/US2004/008429, dated Aug. 17, 2004, 7 pages. cited by other
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Written Opinion of the International Searching Authority, mailing
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Office Action from U.S. Appl. No. 10/261,805, mailed Jan. 26, 2005.
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International Preliminary Report on Patentability in International
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Primary Examiner: Stephens; Jacqueline F.
Attorney, Agent or Firm: Kubicki; H. Michael
Parent Case Text
This application is a divisional of U.S. application Ser. No.
11/330,422, filed Jan. 11, 2006, now U.S. Pat. No. 7,419,562 which
is a continuation of U.S. application Ser. No. 10/452,299, filed
Jun. 2, 2003, which is a continuation-in-part of U.S. application
Ser. No. 10/261,805, filed Oct. 1, 2002, now U.S. Pat. No.
6,979,380 the entire disclosures of which are hereby incorporated
herein by reference.
Claims
What is claimed is:
1. A disposable undergarment comprising: an elasticized front body
panel comprising a pair of opposite first side edges, a first waist
edge and a first crotch edge spaced from said first waist edge; an
elasticized rear body panel comprising a pair of opposite second
side edges, a second waist edge and a second crotch edge spaced
from said second waist edge; wherein said crotch edges of each of
said front and rear body panel webs comprises at one peak and at
least one valley, each of said front and rear body panels having a
minimum rise defined between said valley of each of said respective
front and rear body panels and said first and second waist edges
respectively, each of said front and rear body panels having a
maximum rise defined between said peak of each of said respective
front and rear body panels and said first and second waist edges
respectively, wherein said valleys defining said minimum rises form
at least in part leg opening portions of said front and rear body
panels, wherein each peak defining each of said maximum rises is
aligned with a longitudinally extending centerline of the
undergarment, wherein said crotch edges of said front and rear body
panels are spaced apart and form a gap therebetween in a
non-overlapping relationship; and a crotch member bridging said gap
and having opposite end portions connected to said front and rear
body panels respectively, wherein said crotch member does not cover
said valleys defining said minimum rises of each of said front and
rear body panels.
2. The disposable undergarment of claim 1 wherein each of said
crotch edges of said front and rear body panels includes a curved
portion and a linear portion.
3. The disposable undergarment of claim 2 wherein said crotch edges
of said front and rear body panels are complementary.
4. The disposable undergarment of claim 1 wherein each of said
crotch edges of said front and rear body panels includes a curved
convex shaped portion and a curved concave shaped portion.
5. The disposable undergarment of claim 1 wherein at least a
portion of said leg opening portions are elasticized.
6. The disposable undergarment of claim 5 wherein at least a
portion of said leg opening portions comprises at least one elastic
thread disposed adjacent said crotch edge of each of said front and
rear body panels.
7. The disposable undergarment of claim 1 wherein said crotch
member comprises an absorbent insert.
8. The disposable undergarment of claim 7 wherein said absorbent
insert comprises a top sheet, a back sheet and a retention portion
disposed between said top sheet and said backsheet.
9. The disposable undergarment of claim 8 wherein said crotch
member comprises a base panel having opposite side edges and at
least a pair of folds extending from said side edges of said base
panel, wherein said at least said pair of folds are formed by at
least one of said top sheet and said backsheet.
10. The disposable undergarment of claim 9 wherein said at least
said pair of folds comprises a pair of first folds extending
inwardly from said side edges of said base panel.
11. The disposable undergarment of claim 9 wherein said crotch
member is substantially C-shaped in cross-section.
12. The disposable undergarment of claim 9 wherein said pair of
folds each have a garment side surface secured to first and second
garment side surfaces of said front and rear body panels.
13. The disposable undergarment of claim 9 wherein said at least
said pair of folds comprises a pair of first folds connected to
said side edges of said base panel and a pair of second folds
connected to said first folds along a pair of folding edges.
14. The disposable undergarment of claim 13 wherein opposite side
portions of said crotch member are each substantially z-shaped in
cross-section.
15. The disposable undergarment of claim 9 wherein said retention
portion is disposed only along said base portion and does not form
any portion of said pair of folds.
Description
BACKGROUND
The present invention relates generally to disposable
undergarments, and in particular, to a three-piece undergarment
having a folded crotch member and to the method for the manufacture
thereof from a nested front and rear body panel web.
Disposable undergarments can be configured in many different forms.
For example, disposable absorbent garments can be configured as a
pant-type, pull-on garment, or as a diaper-type product that is
drawn up between the legs and fastened about the waist with various
fastening systems. Often, absorbent garments include an outer
cover, which forms at least a part of a body panel that is secured
around the waist of the user. In addition, the outer cover
typically extends along a crotch region of the garment.
Often, the outer cover is made from a single piece of material,
with leg openings cut therein, for example by die cutting. The
material from the leg cut out, which can account for as much as
20-30% of the total area of the outer cover, typically is waste
material, which must be disposed of or recycled. In addition, the
size of the leg openings formed by a die cutter in a conventional
one-piece outer cover is typically fixed. As such, it can be
expensive and time consuming, and reduces the overall flexibility
of the manufacturing line, to switch dies and alter the process to
manufacture different size garments.
In response to this problem of waste, some garments are configured
with front, rear and crotch sections formed from a single web that
is divided into two nested halves, as disclosed for example in U.S.
Pat. No. 5,858,151 and Japanese Patent Application 03-176053 A.
However, the webs of the U.S. Pat. No. 5,858,151 have overlapping
crotch portions that are directly secured one to the nested halves,
as disclosed for example in U.S. Pat. No. 5,858,151 and Japanese
Patent Application 03-176053 A. However, the webs of the U.S. Pat.
No. 5,858,151 have overlapping crotch portions that are directly
secured one to the other. Accordingly, the overall rise of the
garment is not readily varied to accommodate different size users,
and the range of sizes is limited by the extent of the overlapping
regions.
Conversely, the diaper body of Japanese Patent Application
03-176053 A is positioned over the cut-out portions of a front and
back waistband, such that the exposed portion of the waist bands
defining in part the leg holes are linear. Instead, the shape of
the leg hole is determined by the cut shape of the diaper body,
which produces excess material that must be disposed of or
recycled.
In addition, crotch members are often secured to the bodyside of
the body panels or integrated therein, rather than being secured to
the garment side thereof. Accordingly, the body panels can restrict
the expansion of the crotch member, for example when an absorbent
insert is insulted by the user.
U.S. Pat. Nos. 6,217,563 and 6,264,641, the entire disclosures of
which are hereby incorporated herein by reference and which are
both assigned to Kimberly-Clark Worldwide, Inc., the Assignee of
the present application, disclose securing an expandable absorbent
composite to a garment side of a pair of spaced apart body panels.
The '563 and '641 patents disclose that the inboard edges of the
body panel are straight or curved, and in one particular
arrangement are concave-inward.
In addition, the crotch member, which is often configured as an
absorbent insert, is typically not stretchable. Often, the
non-stretchable crotch member is secured across its entire width,
so as to reduce or otherwise impede the elongation of the body
panel and thereby adversely affecting its ability to conform to the
body of the user.
Therefore the need remains for improved methods and assemblies for
manufacturing undergarments to reduce the waste of materials while
providing improved comfort for the user and flexibility in
manufacturing different size garments.
SUMMARY
Briefly stated, in one embodiment described below, a disposable
absorbent garment includes a front body panel having a first
bodyside surface, a first garment side surface, a pair of opposite
first side edges, a first waist edge and a first crotch edge
defining a first lobe having a first profile in plan view that
extends outwardly relative to the first waist edge. The first lobe
has a first maximum rise along a first direction at substantially a
centerline of the front body panel. The opposite first side edges
are spaced along a second direction, with the second direction
being substantially perpendicular to the first direction. A rear
body panel has a second bodyside surface, a second garment side
surface, a pair of opposite second side edges, a second waist edge
and a second crotch edge defining a second lobe having a second
profile in plan view that extends outwardly relative to the second
waist edge. The second lobe has a second maximum rise along the
first direction at substantially a centerline of the rear body
panel. The opposite second side edges are spaced along the second
direction. The first lobe of the front body panel is aligned with
the second lobe of said rear body panel. A crotch member includes a
base panel having opposite side edges and at least a pair of folds
extending from the side edges of the base panel. The pair of folds
are connected to the first and second garment side surfaces of the
front and rear body panels respectively. The crotch member is
aligned with and overlaps the first and second lobes of the front
and rear body panels respectively on the first and second garment
sides thereof.
In one embodiment, the crotch member is substantially C-shaped in
cross-section. In another embodiment, side portions of the crotch
member are substantially Z-shaped in cross-section.
In one embodiment, the crotch member is formed as an absorbent
insert. The absorbent insert includes a top sheet, a back sheet and
a retention portion disposed therebetween.
In another aspect, a method of manufacturing an undergarment
includes moving a web of body panel material in a longitudinal
machine direction and cutting the web of body panel material along
the longitudinal machine direction to thereby form a rear body
panel web and a front body panel web each having a maximum rise and
a minimum rise respectively. The maximum rise of each of the rear
and front body panel webs is greater than the minimum rise of a
corresponding one of the rear and front body panel webs. The method
further includes shifting at least one of the rear and front body
panel webs in the longitudinal machine direction and thereby
aligning the maximum rises of the rear and front body panel webs.
The method further includes centering a crotch member with the
maximum rises of the rear and front body panel webs and connecting
the crotch member to a garment side surface of the front and rear
body panels.
In one embodiment, the cutting of the web of body panel material
along the longitudinal machine direction includes forming a
substantially sinusoidal pattern defining the maximum and minimum
rises of each of the rear and front body panel webs.
In one embodiment, the front and rear body panel webs are cut along
the lateral cross direction proximate the minimum rise of each of
the front and rear body panel webs. Also in one embodiment, the
crotch member is folded.
In another aspect, a die is used to cut the web of body panel
material. In one embodiment, the method includes forming a cut edge
along each of the front and rear body panel webs, wherein the cut
edges of the front and rear body panel webs have a first and second
shape respectively. In one embodiment, the first shape is different
than the second shape.
In another aspect, the wave pattern defining the cut edges of the
front and rear body panel webs is not symmetrical relative to a
centerline extending in the longitudinal machine direction. In
particular, the curve defining the cut edge on one side of the
centerline has a different shape than the curve defining the cut
edge on the other side of the centerline. In one example, the
curves, if continuous on both sides of the centerline, would have a
different wavelength.
In another aspect, one embodiment further includes elongating the
web of body panel material in the longitudinal machine direction
before cutting the web of body panel web. In this way, the pitch of
the garment can be easily changed simply by varying the amount of
elongation introduced into the web before the web is cut.
In yet another aspect, one embodiment of the method further
includes varying a gap formed between the maximum rises of each of
the rear and front body panel webs. In this way, the overall rise
of the garment can be easily changed simply by varying the gap.
In various embodiments, elastic elements are positioned along one
or more of the outer lateral edges of the inner cut edge of one or
more of the webs.
In another embodiment, the crotch member is formed of an
elastic/stretchable material. In one particular embodiment, one or
both of a top sheet and backsheet, with a retention portion
disposed therebetween, are stretchable and include an elastic
material.
In another aspect, a method includes stretching at least one of the
back sheet and top sheet. In yet another aspect, a method includes
instructing a user on the user of a disposable undergarment is
provided.
The various aspects provide significant advantages over other
disposable undergarments and methods. For example and without
limitation, the nested body panels of one embodiment maximize the
area of body coverage while minimizing and virtually eliminating
the amount of waste material. In addition, by securing the crotch
member to the garment side surface of the body panels and centering
it over the lobes, a unique gasket system is created that maintains
a close fit of the garment to the body of the user while allowing
the crotch member, e.g., an absorbent insert, to expand outwardly
from the skin. In addition, the lobes of the front and rear body
panels provide a physical barrier between a wet absorbent insert
and the skin of the user.
The foregoing paragraphs have been provided by way of general
introduction, and are not intended to limit the scope of the
following claims. The presently preferred embodiments, together
with further advantages, will be best understood by reference to
the following detailed description taken in conjunction with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a system for manufacturing an
absorbent garment.
FIG. 2 is a plan view of a web of body panel material being cut
along a longitudinal machine direction.
FIG. 3 is a plan view of a front and rear body panel web with a
plurality of absorbent inserts being applied thereto.
FIG. 4 is a plan view of one embodiment of an absorbent garment in
an unfolded configuration.
FIG. 5 is a plan view of another embodiment of an absorbent garment
in an unfolded configuration.
FIG. 6 is a plan view of a web of body panel material being cut
along a longitudinal machine direction.
FIG. 7 is a plan view of a front and rear body panel web separated
in the cross direction and aligned in the machine direction.
FIG. 8 is a garment having a front and rear body panel web formed
from the webs shown in FIG. 7.
FIG. 9 is a plan view of another embodiment of an absorbent garment
in an unfolded configuration.
FIG. 10 is a cross sectional view of the absorbent garment shown in
FIG. 9 taken along line 10-10.
FIG. 11 is a cross sectional view of the absorbent garment shown in
FIG. 9 taken along line 11-11.
FIG. 12 is an alternative cross-sectional view of the absorbent
garment shown in FIG. 9 taken along line 12-12.
DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS
It should be understood that the term "longitudinal," as used
herein, means of or relating to length or the lengthwise direction.
The term "laterally," as used herein means situated on, directed
toward or running from side to side.
The term "bodyside" should not be interpreted to mean in contact
with the body of the user, but rather simply means the side that
would face toward the body of the user, regardless of whether an
undergarment is actually being worn by the user and regardless of
whether there are or may be intervening layers between the
component and the body of the user. Likewise, the term "garment
side" should not be interpreted to mean in contact with the
garments of the user, but rather simply means the side that faces
away from the body of the user, and therefore toward any outer
garments that may be worn by the user, regardless of whether the
undergarment is actually being worn by a user, regardless of
whether any such outer garments are actually worn and regardless of
whether there may be intervening layers between the component and
any outer garment.
The term "machine direction" means the direction of flow as the
various members and webs progress along the fabrication line and
process. It should be understood that various separate members or
webs can each be traveling in a machine direction, but with the
various machine directions not necessarily being parallel or
oriented in the same direction. For example, a first component such
as a web may be traveling a first machine direction, which is
substantially perpendicular to the travel of another component,
such as an absorbent insert, in a second machine direction.
The term "cross direction" means the direction substantially
perpendicular to the machine direction.
The term "downstream" means that one item is positioned more
closely to the output or finished product end of the machine and/or
process relative to another item. Conversely, the term "upstream"
means that an item is positioned more closely to the input end of
the machine or process relative to another item. For example, the
output end is downstream of the input end, and vice versa, the
input end is upstream of the output end.
The phrases "removeably attached," "removeably attaching,"
"removeably connected," "removeably engaged," "releasably
attached," "releasably connected," or "releasably engaged," and
variations thereof, refers to two or more elements being connected
or connectable such that the elements tend to remain connected
absent a separation force applied to one, both or all of the
elements, and where the elements are capable of being separated
upon the application of a separation force. The required separation
force is typically beyond that encountered while wearing the
absorbent garment.
The phrases "fixedly secured," "fixedly engaged," "fixedly
attached," "fixedly connected," and variations thereof, refers to
two or more elements being connected or connectable such that they
are not disconnected or otherwise separated, and are not intended
to be separated or disconnected, during the normal operation and
use of the absorbent garment.
The term "web" refers to a continuous stream of material, whether
made from one or more layers or substrates, and regardless of
whether it may have non-continuous, discrete items disposed
thereon.
The terms "connecting," "coupled," "attached," and "secured," and
variations thereof, broadly covers two or more items being directly
connected one to the other, or by way of one or more intervening
members or components.
Referring to FIGS. 4, 5 and 9, an undergarment 2 includes a first,
front body panel 4 and a second, rear body panel 6. The term "body
panel" refers to the portion(s) of the undergarment, whether made
of one or more layers or substrates or of one or more pieces or
components, that is/are fitted circumferentially around at least
the waist region of the user, including for example the user's
lower back, buttock, hips and abdomen. The first and second body
panels each have an inner, bodyside surface 10 and an outer,
garment side surface 12. The first, front body panel 4 has a first
edge 14 forming a crotch portion 16 and leg opening portion 18 and
a second terminal edge 20 which, in one embodiment, is linear but
can assume other shapes. Likewise, the second, rear body panel 6
has a first edge 22 forming a crotch portion 24 and a leg opening
portion 26 and a second terminal edge 28, which is shown linear but
can assume other shapes. Each of the first and second body panels
has an outboard side edge 30, 32 formed along the outer periphery
of the opposite side portions of the first and second body panel.
It should be understood that the outboard side edges of the front
and rear body panels can have different lengths relative to each
other.
Referring to FIG. 5, one or more, and in one embodiment a
plurality, meaning two or more, elastic elements 36 are secured to
each of the first and second body panels. In preferred embodiment,
a plurality of elastic elements are spaced across substantially the
entire waist portion of the front and rear body panel 4, 6,
although they may be spaced across a lesser length. For example,
elastic elements can extend along the upper waist portion and along
the lower terminal edge defining in part a leg opening 34.
In one embodiment, the front body panel has a "non-elasticized"
area wherein there are no elastic elements, or other elastic or
elastomeric backing members, incorporated therein or making up any
portion of the thickness or cross-section of the body panel at that
area. It should be understood, that in an alternative embodiment,
one or more separate waist bands, with or without elastic elements,
can be secured to one or both of the rear and front body panels,
preferably along the upper terminal edges 20, 28 thereof. Likewise,
one or more separate leg bands can be secured to one or both of the
rear and front body panels along the leg open portions 18, 26
adjacent the leg openings 34. Alternatively, one or both of the
body panels can be formed without any elastic elements as shown in
FIG. 4.
The various waist and leg elastic elements can be formed from
rubber or other elastomeric materials. One suitable material is a
LYCRA.RTM. elastic material. For example, the various elastic
elements can be formed of LYCRA.RTM. XA Spandex 540, 740 or 940
decitex T-127 or T-128 elastics available from E.I. duPont De
Nemours and Company, having an office in Wilmington, Del.
Referring to the embodiments of FIGS. 4, 5, 9, 10 and 12, each body
panel 4, 6 is formed as a composite, or laminate material,
otherwise referred to as substrates or laminates, with the
plurality of elastic strands or an elastomeric substrate 204
sandwiched therebetween. In one embodiment, the elastic substrate
is made of an elastomeric film or nonwoven elastic or stretchable
material including for example but not limited to styrenic
copolymers of polyisoprene, polybutadiene or polyolefin, copolymers
of polyolefins, natural or styrene butadiene rubber, polyurethanes,
polyamides, polyesters, and co-extrusions/blends of the
aforementioned materials. The elastic substrate or core can be
formed as a membrane or from a plurality of elastic strands.
Preferably two or more layers 202 are bonded with various
adhesives, such as hot melt, or by other techniques, including for
example and without limitation ultrasonic bonding and heat pressure
sealing. In one embodiment, the two layers are made of a non-woven
material such as a spunbond material, a bonded carded material or
other known materials. It should be understood that the body panels
can be made of a single layer or substrate of non-woven material,
or can be comprised of more than two layers or substrates. Of
course, it should be understood that other knitted or woven
fabrics, non-woven fabrics, elastomeric materials, polymer films,
laminates and the like can be used to form one or more of the body
panel layers. The term "non-woven" web or material, as used herein,
means a web having a structure of individual fibers or filaments
that are interlaid, but not in an identifiable manner and without
the aid of textile weaving or knitting, as in a knitted or woven
fabric.
In one embodiment, the body panel material can be secured to the
elastic elements, such as a elastomeric web, strands or ribbons,
which have been elongated and retracted, such that the material is
gathered when the elastic elements are relaxed. Alternatively, the
material can be gathered and laminated to non-elongated elastic
elements. In one embodiment, the body panel includes a gathered
elastic laminate made from nonwoven base sheets bonded with
elongated elastic element(s) sandwiched therebetween.
In various embodiments, the body panel material may be
substantially permeable to air or substantially impermeable to air.
The body panel material also may be substantially liquid-permeable
or substantially liquid-impermeable. In particular arrangements,
the body panel material may be substantially nonelastomeric. In
other aspects, the body panels can include an elastomeric material
that is elastomerically stretchable at least along the lateral
article width. Examples of such elastomeric composite materials can
include a continuous filament stretch bonded laminate (CFSBL), a
vertical filament laminate (VFL), neck-bonded-laminate (NBL), a
stretch-bonded-laminate (SBL), a necked-stretch bonded laminate
(NSBL) or a necked-thermal laminate, or the like, as well as
combinations thereof. Exemplary CFSBL, NBL, SBL, and NSBL materials
are described in U.S. Pat. Nos. 5,226,992, 4,981,747, 4,965,122,
5,336,545, 5,385,775, 5,414,470, 4,720,415, 4,789,699, 4,781,966,
4,657,802, 4,652,487, 4,655,760, 5,116,662, 5,114,781 and
6,323,389, all of which are hereby incorporated herein by
reference. Exemplary VFL materials are described in U.S.
Provisional Patent Application Ser. No. 60/204,307, filed May 15,
2000 and entitled "Method and Apparatus for Producing Laminated
Articles," and PCT application WO 01/88245 A2, both assigned to
Kimberly-Clark Worldwide, Inc., the Assignee of the present
application, with the entire disclosures of both being hereby
incorporated herein by reference. Such laminates can provide an
improved combination of cloth-like feel and elastomeric
stretchability. The body panels can be composed of materials that
are elastic or elastomeric and exhibit biaxial stretch
characteristics or MD/CD stretch characteristics, or that are
extensible composites. Additional waist and leg elastic elements
can be added to, but are not necessarily required by, the body
panels.
In one embodiment, the entirety of the body panels are elasticized,
such that the entire body panel conforms to the body of the user
without any spacing between the body panel and the user's body, and
without the attendant bulkiness of a non-elasticized material.
In various embodiments, the body panels are breathable, cloth-like,
multi-directional nonwoven laminates with stretch and/or extensible
properties. In one embodiment, the non-woven layers are pre-necked,
for example between about 10% and about 80%, in the longitudinal
direction, which provides extensibility in the longitudinal
direction with minimum force.
The terms "extensible," "extensibility," and variations thereof as
used herein means capable of being extended, and providing a
selected elongation, for example between about 5% and about 70%,
when subjected to an applied tensile force. The body panel also is
preferably capable of providing a selected, sustained deformation
when subjected to an applied tensile force and then allowed to
relax for a selected time period beginning immediately after
removal of the tensile force. The sustained deformation is a
substantially permanent deformation. The selected elongation and
sustained deformation preferably occur at least along the
longitudinal direction of the garment, although it should be
understood that it also could occur along the lateral direction, or
both. Various extensible materials, and other acceptable materials
that can be used for the body panels are described for example in
U.S. Pat. No. 6,217,563, issued Apr. 17, 2001 to Kimberly-Clark
Worldwide, Inc., the same Assignee as the present application, the
entire disclosure of which is hereby incorporated herein by
reference.
The extensibility of the non-woven material provides an increase in
surface area without the retractive force of elastomeric materials.
In one embodiment, body panel is extensible in at least the
cross-direction, or longitudinal direction, with the material
providing an elongation of at least about 1 cm when subjected to a
tensile force of 11.8 grams per cm. In addition, the body panel
provides a substantially permanent deformation of at least about
20% when it is subjected to a tensile force of 19.70 grams per cm
and is then allowed to relax under a zero applied stress for a
period of 1 minute. Of course, it should be understood that the
body panel can also be made extensible in the lateral direction. A
suitable technique for generating a representative tensile-load v.
extension curve, and for determining the amount of elongation
and/or retractive force parameters of a selected component or
material can employ ASTM Standard Test Method D882 (Tensile Method
for Tensile Properties of Thin Plastic Sheeting) dated December
1995, with the following particulars. The "width" of the test
sample will be a cross-wise width which can be conveniently
obtained from the product being tested, and is desirably about 2
inch (about 5.04 cm). The test sample width is perpendicular to the
direction of the tensile force applied during the testing. With
regard to the shown configurations, for example, the test sample
"width" generally corresponds to the length-wise dimension of the
component along the longitudinal direction of the article. The
initial separation of the jaws of the tensile tester is 3 inches
(7.62 cm), and the moving jaw is moved at a constant rate of 50
mm/min. The moving jaw is stopped at an extension of 50 mm for a
period of 10 sec, and then returned back to its initial starting
position at a rate of 50 mm/min. The force-extension curve to the
complete tension and retraction cycle can be recorded on a
conventional computer equipped with commercially available
software, such as TestWorks for Windows, version 3.09, which is
available from MTS System Corporation, a business having a location
at 14000 Technology Drive, Eden Prairie, Minn. The obtained data is
normalized and reported in appropriate units of force per unit
length of sample "width" (e.g. grams-force per inch, or Newtons per
inch, or grams-force per centimeter, or Newtons per
centimeter).
In one embodiment, the front and rear body panels 4, 6 are made of
non-woven laminates of two layers of longitudinally extensible 0.60
osy polypropylene spunbond material with elongated strands of
Lycra.RTM. elastic sandwiched between the spunbond layers and
thereafter adhesively bonded. In particular, the body panel
material is necked in the cross direction. As used herein, the term
"necked," and variations thereof, refers to any material that has
been constricted in at least one dimension by applying a tensioning
force in a direction that is perpendicular to the desired direction
of neck-down. Processes that may be used to constrict a material in
such a manner include, for example and without limitation, drawing
processes. The elastics are then elongated in the machine direction
and secured to the body panel material. The elastics are then
allowed to retract so as to gather the necked spunbond material in
the lateral (machine) direction thereby creating an elastically
gathered non-woven body panel with longitudinal extensibility. The
term "gather," and variations thereof, as used herein means
puckered, or contracted into folds or wrinkles, which should be
understood as including micro-pleats.
In this way, the body panel can be elongated in both the
longitudinal and lateral direction to conform to the body of the
user when the garment is applied thereto. In particular, as the
user pulls the garment up over their hips, the non-woven laminate
body panels stretch in the lateral direction while the leg regions
of the front and rear body panels conform to the crotch and body
lines of the user. At the same time, the body panel material
extends in the longitudinal direction to conform to the buttocks
and stomach of the user. The extensibility of the body panels
follows the natural curvature of user's body to provide conformance
thereto. As the body panel extends in the longitudinal direction,
the spacing between the laterally extending elastic elements 36,
incorporated in one embodiment, will increase.
In one embodiment, the body panel non-woven material is
substantially hydrophobic, which may optionally be treated with a
surfactant or otherwise processed to impart a desired level of
wettability and hydrophilicity. In one particular embodiment of the
invention, the body panel is a nonwoven, wire-weave spunbond
polypropylene fabric composed of about 1.6 denier fibers formed
into a web having a basis weight of about 0.6 osy. One suitable
non-woven material is the Corinth 0.60 osy, 1.6 dpf wireweave,
nonwettable Metallocene (EXXON ACHIEVE 2854 PP) spunbond material
manufactured by Kimberly-Clark Corporation, the Assignee of the
present application.
Referring to FIGS. 4 and 5, a crotch member 50 connecting the front
and rear body panels 4, 6 can be folded such that the side edges
30, 32 of the front and rear body panels 4, 6 are aligned wherein
they can be fixedly secured at a seam. The seam can be formed by
bonding, sewing or otherwise attaching the side edges.
Alternatively, the product can remain "open," wherein the body
panels are releasably secured with one or more fastening members as
explained below.
In one embodiment the garment includes a combination of side edges
that are secured to form a seam and fastening members that allow
the fit of the undergarment to be adjusted. For example, fastening
members are preferably attached to the front body panel and extend
inboard relative to the outboard side edge 30 of the front body
panel 4 from an attachment location, which is preferably spaced
inboard from the side edge. A landing member can be formed on or
secured to the body panel to receive a refastenable portion of the
fastening member. One or more lines of weakness can be provided
along the front or rear body panel such that one or both of the
body panels are breakable. The lines of weakness can comprise a
perforation or other series of cuts, a thinning, breakage or
separation of material, or a strip of a different kind of material
bridging portions of the body panel that is more easily torn or
broken than the other material thereof, which allow a user or the
manufacturer to separate portions of the body panel. For example,
the undergarment can be broken along the lines of weakness after
the garment is applied to a user, or beforehand.
It should be understood that, in other embodiments, the fastening
members can be secured to the rear body panel and engage the front
body panel or, conversely, can be secured to the front body panel
and engage the rear body panel, for example along at least a
portion that is not elasticized. In one embodiment, the fastening
members are fixedly secured to the outer, garment-side surface of
the front and/or rear body panels, and releasably engage the outer,
garment-side surface of the front and/or rear body panels, although
it should be understood that the fastening members could be fixedly
secured to an inner body-side surface of front and/or rear body
panels and releasably engage an inner, body-side surface of the
front and/or rear body panels.
When incorporated into a disposable absorbent undergarment, in one
embodiment, the fastening members include a refastenable portion,
such as an array of hook members, adhesives, such as pressure
sensitive adhesives, buttons, zippers, snaps and other releasable
and reattachable fastening devices. In various embodiments, the
fastening member includes one, two or more than two tab members. In
one embodiment, the fastening members comprise a carrier member,
which is preferably fixedly secured to the side portions of the
front body panel with adhesive bonds, sonic bonds, thermal bonds,
pinning, stitching or other known types of attachment. In
alternative embodiments, the fastening members can be fixedly
secured to the rear body panel or to one or both of the front and
rear body panels, for example, at the seam, as explained above.
Referring to FIGS. 4, 5 and 9, in one embodiment the undergarment
is disposable and is also configured as an absorbent undergarment.
In the absorbent garment, the crotch member 50 is configured as an
absorbent insert having first and second opposed terminal end edges
60, 62.
In various embodiments, shown in FIGS. 9-12, the absorbent insert
crotch member 50 preferably includes a substantially liquid
permeable topsheet 206, or liner, a substantially liquid
impermeable barrier layer or backsheet 208, and an outer cover 210,
which is made in one embodiment of a non-woven material that
provides a cloth-like feel. The outer cover may be omitted in some
embodiments. A retention portion 212 is disposed or sandwiched
between the topsheet and the backsheet, which are connected. The
topsheet, backsheet and other components of the absorbent insert 50
can be joined for example with adhesive bonds, sonic bonds, thermal
bonds, pinning, stitching or any other attachment techniques known
in the art, as well as combinations thereof. For example, a uniform
continuous layer of adhesive, a patterned layer of adhesive, a
sprayed pattern of adhesive or any array of lines, swirls or spots
of construction bonds may be used to join the topsheet and
backsheet, or any of the other components described herein.
It should be understood that the term "absorbent insert" refers to
any material or assembly capable of absorbing liquids or bodily
exudates, and may be comprised of a single material or component,
for example a retention portion, or can be formed as a composite of
several components. It should also be understood that the term
"crotch member" refers to any member made of any material,
including for example and without limitation those described herein
with respect to the body panels and absorbent inserts, and is not
limited to absorbent inserts and/or materials. For example, the
crotch member may be made of one or more layers of a non-woven
material.
In one embodiment, additional layers, including for example, a
surge layer, are also preferably incorporated into the absorbent
insert. Preferably, the surge layer does not run the entire length
of the absorbent insert and is shorter than the retention portion.
The topsheet can be indirectly joined to the backsheet by affixing
the topsheet to intermediate layers, such as the surge layer or
retention portion, which in turn is affixed to the backsheet. The
absorbent insert also may include barrier cuffs, or leakage control
shields, formed along the opposite longitudinally extending edges
of the absorbent composite.
Referring to FIGS. 9-11, the absorbent insert has a base panel 214
and a pair of folds 218 extending laterally inward from and joined
to the base panel 214 at opposite folded side edges 216. The pair
of folds 218 and base panel 214 provide the absorbent insert with a
C-shape configuration in cross-section. The garment side 226 of the
folds are secured to the garment side 12 of the body panels 4, 6 at
an attachment location 220, for example adjacent a free edge 222 of
the folds. Referring to FIG. 9, the attachment location can extend
continuously and longitudinally along the portion of the crotch
member that overlaps the front and rear body panels, or in other
embodiments, the attachment locations can be configured as one or
more discrete and spaced-apart attachment locations.
Referring to FIGS. 9-11, the folds 218 can be formed from any
combination of the top sheet 206, the backsheet 208, the outer
cover 214, retention portion 212, or any other component. For
example, as shown in FIGS. 10 and 11, the folds 218 are formed from
a combination of the topsheet 206, backsheet 208 and outer cover
214. In other embodiments, only one of those components, e.g., the
backsheet or top sheet, forms the fold, and in other embodiments,
some subcombination thereof forms the folds, for example the outer
cover and backsheet but not the top sheet or retention portion. It
should be understood that the retention portion can also include
folds that are interfolded with the folds of the backsheet and top
sheet. Each of the individual layers may also have an edge folded
back over itself.
Referring to FIGS. 10 and 11, one or more longitudinally extending
crotch elastics 224 are disposed between and secured to the
topsheet and backsheet using various methods described above. The
crotch elastics 224 extend along the sides of the crotch member and
overlap in one embodiment a portion of the front and rear body
panel, as shown in FIG. 9. The crotch elastics provide a gasket
against the body of the user.
It should be understood that any number of folds can extend from
the base panel. For example, as shown in FIG. 12, the absorbent
insert 50 includes a pair of first folds 218 extending from
opposite first folded edges 216 formed at the juncture with the
base panel, and a pair of second folds 230 extending from opposite
second folded edges 234 formed at the juncture with the first
folds. In this embodiment, a bodyside surface 232 of the absorbent
insert, and in particular the second folds, are secured to the
garment side surface 12 of the body panels 4, 6. As with the
embodiment of FIGS. 9-11, the first and second folds 218, 230 can
be formed from any combination of the various layers of the
absorbent insert, including the backsheet, the top sheet, the outer
cover and the retention portion. In addition, crotch elastics 224,
which can include in various embodiments one or more strands, are
disposed between two or more of the layers in one or both of the
first and second folds 218, 230. In the embodiment of FIG. 12,
opposite side portions 236 of the absorbent insert have a Z-shape
in cross-section. It should be understood that other embodiments
may include more than two folds on each side of the absorbent
insert. For example, each side portion may be formed as a
multi-pleated configuration. Alternatively, the absorbent insert
may not have any folds, and may be formed from a single layer,
having a body side surface secured to the garment side surface of
the body panels.
The backsheet is preferably liquid impermeable, but may be liquid
permeable, e.g., when an additional barrier layer is used with the
retention portion. For example, in one embodiment, the backsheet
can be made from a thin plastic film, or other flexible,
substantially liquid-impermeable material. As used herein, the term
"flexible" means a material that is compliant and which will
readily conform to the general shape and contour of the body of the
user. The backsheet prevents various bodily fluids and exudates
from wetting or otherwise contaminating various bedding or outer
garments worn by the user over the absorbent garment. In
particular, the backsheet can include a film, such as a
polyethylene film, having a thickness of from about 0.012 mm to
about 0.051 mm.
In various constructions, the topsheet can include various woven or
nonwoven materials and laminates, which can be stretchable or
extensible. In one embodiment, the top sheet is an extensible
material. For example, the topsheet can be composed of a meltblown
or spunbonded web of desired fibers, and may also be a
bonded-carded web. For example, the topsheet can be made of a
substantially hydrophobic material, and the hydrophobic material
may optionally be treated with a surfactant or otherwise processed
to import a desired level of wettability and hydrophilicity. In one
particular embodiment of the invention, the topsheet is a nonwoven,
spunbond polypropylene fabric composed of about 2.8-3.2 denier
fibers formed into a web having a basis weight of about 22 gsm and
density of about 0.06 gm/cc. The fabric can be surface treated with
an operative amount of surfactant, such as about 0.28% Triton X-102
surfactant. The surfactant can be applied by any conventional
means, such as spraying, printing, brush coating or the like.
In various constructions, the backsheet can comprise a woven or
nonwoven fibrous web layer, which is treated or constructed,
partially or wholly, to impart the desired levels of liquid
impermeability to selected regions that are adjacent to or
proximate the absorbent retention portion. For example, the
backsheet may include a gas-permeable, nonwoven fabric layer
laminated to a polymer film layer which may or may not be
gas-permeable. Other examples of fibrous, cloth-like backsheet
materials can comprise a stretch thinned or stretch thermal
laminate material composed of a 0.6 mil (0.015 mm) thick
polypropylene cast film and a 0.7 ounce per square yard (23.8 gsm)
polypropylene spunbond material (2 denier fibers). A material of
this type has been employed to form the outercover of a
HUGGIES.RTM. Ultratrim Disposable Diaper, which has been
commercially available from Kimberly-Clark Corporation. The
backsheet can provide the outercover of the article, particularly
in the crotch region. Optionally, however, the article may include
a separate outercover component member, as disclosed herein, which
is additional to the backsheet. The outercover can be joined, for
example, to one or more of the absorbent composite and/or body
panels as explained above.
In one embodiment, the retention portion 212, and other components,
such as a transfer layer (not shown) and tissue layers (not shown),
are free floating (unattached) between the back sheet 208 and the
top sheet 206, which are secured along only the peripheral edges
thereof. Alternatively, the retention portion, transfer layer and
other components are minimally attached to one or both of the back
sheet 208 and top sheet 206. For example, the retention portion can
be secured to the back sheet along an attachment location
positioned along the longitudinal centerline of the retention
portion. Alternatively, or in combination with the back sheet
connection, the transfer layer or retention portion can be
minimally attached to the top sheet. In this way, the retention
portion 212, and other components, do not impede or substantially
affect the lateral stretchability and extensibility of the
absorbent insert 50 and in particular the top sheet and back sheet,
at least one of which is secured to the body chassis.
In other embodiments, the top sheet is indirectly joined to the
backsheet by affixing the topsheet to intermediate layers, such as
the surge layer or retention portion, which in turn is affixed to
the backsheet. The absorbent insert also may include barrier cuffs,
or leakage control shields, formed along the opposite
longitudinally extending edges of the absorbent composite.
In one embodiment, the back sheet 208 is a stretchable, elastic,
liquid impervious member. Alternatively, the back sheet may be
liquid permeable, e.g., when an additional barrier layer is used
with the retention portion. In one embodiment, the back sheet 208
is a laminate structure made of a stretchable, elastic material,
such as an elastomeric film, which is laminated to an extensible
non-woven material layer. It should be understood that the
backsheet can be formed from a single layer or substrate or more
than two layers or substrates. Various backsheet and topsheet
materials are described in U.S. application Ser. No. 10/325,500,
filed Dec. 19, 2002, entitled "Disposable Undergarment With A
Stretchable Absorbent Insert and Method For the Use Thereof," and
assigned to Kimberly-Clark Worldwide, Inc., the Assignee of the
present application, the entire disclosure of which application is
hereby incorporated herein by reference.
The backsheet may include a micro-porous, "breathable" material
which permits gases, such as water vapor, to escape from the
absorbent garment while substantially preventing liquid exudates
from passing through the backsheet. For example, the breathable
backsheet may be composed of a microporous polymer film or a
nonwoven fabric which has been coated or otherwise modified to
impart a desired level of liquid impermeability. For example, a
suitable microporous film can be a PMP-1 material, which is
available from Mitsui Toatsu Chemicals, Inc., a company having
offices in Tokyo, Japan; or an XKO-8044 polyolefin film available
from 3M Company of Minneapolis, Minn. The backsheet may also be
embossed or otherwise provided with a pattern or matte finish to
exhibit a more aesthetically pleasing appearance.
In various configurations of the invention, where a component, such
as the backsheet is configured to be permeable to gas while having
a resistance and limited permeability to aqueous liquid, the liquid
resistant component can have a construction which is capable of
supporting a selected hydrohead of water substantially without
leakage therethrough. A suitable technique for determining the
resistance of a material to liquid penetration is Federal Test
Method Standard FTMS 191 Method 5514, 1978, or an equivalent
thereof.
In one preferred embodiment, the backsheet is sufficiently
impermeable to liquid and semi-liquid materials to substantially
prevent the undesired leakage of waste materials, defined as
exudates, including for example urine and feces. For example, the
backsheet member can desirably support a hydrohead of at least
about 45 centimeters (cm) substantially without leakage. The
backsheet member can alternatively support a hydrohead of at least
about 55 cm, and optionally, can support a hydrohead of at least
about 60 cm, or more, to provide improved benefits.
The backsheet and/or outercover also can be extensible. In one
preferred embodiment, the backsheet and/or outercover is capable of
providing an elongation of at least about 1 cm when subjected to a
tensile force of 11.8 g/cm, and further provides a substantially
permanent deformation of at least about 20% when subjected to a
tensile force of 19.70 g/cm and is then allowed to relax under a
zero applied stress for a period of 1 minute.
For example, the extensible member can be composed of a necked
fiber, a creped fiber, a micro-pleated fiber, polymer films or the
like, as well as combinations thereof. The fabrics may be woven or
nonwoven materials, such as spunbond fabrics. One example of a
suitable extensible material is a 60% necked, polypropylene
spunbond having a basis weight of about 1.2 osy.
As explained above, the backsheet and/or outercover also can be
expandable, for example when it has one or more folds, e.g., one or
more z-folds (not shown), or can be both extensible and expandable.
The term expandable as used herein means to enlarge or to increase
the extent or area, lateral and/or longitudinal, thereof, e.g., by
unfolding one or more folds.
The retention portion is preferably made of an absorbent material,
which can be any material that tends to swell or expand as it
absorbs exudates, including various liquids and/or fluids excreted
or exuded by the user. For example, the absorbent material can be
made of airformed, airlaid and/or wetlaid composites of fibers and
high absorbency materials, referred to as superabsorbents.
Superabsorbents typically are made of polyacrylic acids, such as
FAVOR 880 available from Stockhausen, Inc. of Greensboro, N.C. The
fibers can be fluff pulp materials, such as Alliance CR-1654, or
any combination of crosslinked pulps, hardwood, softwood, and
synthetic fibers. Airlaid and wetlaid structures typically include
binding agents, which are used to stabilize the structure. In
addition, various foams, absorbent films, and superabsorbent
fabrics can be used as an absorbent material. Various acceptable
absorbent materials are disclosed in U.S. Pat. Nos. 5,147,343 for
Absorbent Products Containing Hydrogels With Ability To Swell
Against Pressure, 5,601,542 for Absorbent Composite, and 5,651,862
for Wet Formed Absorbent Composite, all of which are hereby
incorporated herein by reference. Furthermore, the proportion of
high-absorbency particles can range from about 0 to about 100%, and
the proportion of fibrous material from about 0 to about 100%.
Additionally, high absorbency fibers can be used such as Oasis type
121 and type 122 superabsorbent fibers available from Technical
Absorbent Ltd., Grimsby, Lincolnshire, United Kingdom.
The retention portion can be made of a single or dual layer of
absorbent material, and can include various folds. The retention
portion preferably has an hour-glass shape with enlarged end
regions. Alternatively, the retention portion can include a folded
or multi-layered configuration. The retention portion preferably
has a length substantially equal to, or slightly shorter than, the
length of the absorbent insert. The retention portion can include
one or more barrier layers attached to the absorbent material. In
one embodiment, an upper tissue substrate is disposed adjacent the
retention portion. Alternatively, a lower tissue substrate can be
disposed adjacent an opposite side of the retention portion, or the
tissue can completely envelope the retention position.
Referring to FIGS. 4 and 5, the opposite garment side of the end
regions of the crotch member 50, and in particular, the outer,
garment side surface of the backsheet, are secured to the bodyside
surface of the opposed crotch portions 16, 24 of the first and
second body panels 4, 6. It should be understood that in
alternative embodiments, shown for example in FIGS. 9-12, the
crotch member 50, for example one or the other of the garment side
or the body side thereof depending on the folded configuration
thereof, can be secured to the garment side surface of the first
and second body panels. It should be understood that the crotch
member 50 can be secured using any of the methods of attachment
described above, including for example various adhesives, stitching
or other bonding methods. The crotch member can be secured to the
body panels with any configuration of attachment lines, swirls,
patterns, spots, etc., or can be a full and continuous attachment
therebetween.
The entire portion of the crotch member 50 overlapping the body
panels 4, 6 can be attached thereto, or the crotch member can be
minimally attached to the body panels, for example by one or more
lines of attachment formed along the centerline of the absorbent
composite, or along a line adjacent the crotch portions 16, 24 of
the body panels, so as to allow the body panels to stretch from
side to side and extend from front to back, or from the crotch to
the waist.
Referring to FIGS. 1-8, the method for fabricating one or more
embodiments of the aforedescribed refastenable absorbent garment is
illustrated. Referring to FIGS. 1, 2, 6 and 7, a web 72 of body
panel material is cut in a longitudinal machine direction 74 to
form a front and rear body panel web 76, 78. Preferably, the web 72
is cut in a sinusoidal wave pattern, which should be broadly
interpreted as a pattern having peaks 54, 154 and valleys 56, 156,
with the pattern generally defined by a pitch P and an amplitude A,
A1. The pattern can be formed of undulating curves or wave
patterns, or can include or be made entirely of various linear
portions.
Each body panel web includes an outer lateral edge 80, 82 and an
inner cut edge 84, 86. In one embodiment, shown for example in FIG.
3, the inner cut edges 84, 86 of the front and rear body panel webs
correspond, or mate such that they have the same shape and
amplitude. In such an embodiment, no waste material is
generated.
In an alternative preferred embodiment, shown in FIGS. 6-8, the
wave pattern defining the first and second cut edges 84, 86 has a
first and second shape 102, 104 formed on opposite sides of a wave
baseline 100, which extends in the longitudinal machine direction
approximately half way between the peaks 54, 154 and valleys 56,
156 of the cut edges. In this embodiment, the first shape 102 is
different from said second shape 104, with each shape having a
different curvature. In particular, the first shape 102 has a first
wavelength L1 and the second shape 104 has a second wavelength L2.
Preferably, the first wavelength L1 is greater than the second
wavelength L2. In this way, as shown in FIG. 8, the front body
panel 4 can be provided with a different shape than the rear body
panel 6. For example, the undergarment can be configured as a thong
shaped undergarment with a relatively narrow rear body panel 6.
In another preferred embodiment, a die cutter 101 is used to cut
the web. The die cutter is configured to form inner cut edges 84,
86 on the front and rear body panels having different shapes and
amplitudes A, A1, as shown for example in FIG. 2. In such an
embodiment, a minimal amount of waste material is generated, but it
allows for the front and rear body panels to be specifically shaped
to conform to the body of the user. For example, the shape of the
rear body panel web 78 cut edge 86 can be provided with lesser
amplitude A1 than the amplitude A of the front body panel web 76.
In this embodiment, a minimal amount of waste material 42 is
produced. In one embodiment, one of the body panels is formed with
a wave pattern, or substantially sinusoidal cut edge, while the
other is configured with a straight cut edge. In various
alternative embodiments, the cut edges can be formed by an
oscillating cutter, slitters, water jets, lasers and other known
cutting devices.
In the preferred embodiment, each of the front and rear body panel
webs 76, 78 has a maximum rise (Max R), measured at the peak 54,
154 and forming crotch portion lobes 16, 24 (along the centerline
of the garment), and a minimum rise (Min R), measured at the valley
56, 156. The term "rise," as used herein, means the measured
distance between two edges, for example the outer edge 80, 82 and
the inner cut edge 84, 86 of each of the front and rear body panel
webs 76, 78 respectively. The total rise of the garment is measured
between the outer edges 20, 28 of the front and rear body panels,
or body panel webs, after the crotch member is connected thereto.
Preferably, one or both of the front and rear body panel webs are
shifted in the longitudinal machine direction, as shown to align
the maximum rises, or peaks 54, 154, of the front and rear body
panels, which also results in the alignment of the minimum rises,
or valleys 56, 156, of the front and rear body panels. In a
preferred embodiment, the maximum rises, defining lobes 16, 24 of
the absorbent garment, have a profile in plan view that extends
outwardly relative to the waist edge 20, 28. As shown in FIG. 1, a
first and second conveyor 101, 103 can simply be spaced apart so as
to provide for a longer travel for one of the front and rear body
panel webs 76, 78.
Referring to FIGS. 1 and 2, the front and rear body panel webs 76,
78 are also separated, or shifted, outwardly relative to one
another in the lateral cross-direction 94 so as to form a gap 88
between the cut edges 84, 86 of the front and rear body panel webs
76, 78 at the maximum rise formed at the respective peaks 54, 154.
In various embodiments, the spacing between the cut edges at the
maximum rise of the respective front and rear body panels (i.e.,
the closest spacing between the front and rear body panels) is
preferably between about 1% and about 90% of the total rise of the
garment, more preferably between about 10% and about 60% of the
total rise of the garment, and most preferably between about 20%
and about 40% of the total rise of the garment. In addition, in
various embodiments, the spacing between the cut edges at the
maximum rise of the respective front and rear body panels is
preferably between about 10 mm and about 800 mm, more preferably
between about 50 mm and about 500 mm, and most preferably between
about 100 mm and about 300 mm. In an alternative embodiment, the
cut edges and the crotch portions of the front and rear body panels
overlap, and can be secured one to the other. In such an
embodiment, the panels can be separated slightly, or can simply be
shifted in the longitudinal direction without any lateral
separation.
In one embodiment, the front and rear body panel webs 76, 78 are
separated such that no portions of either web overlap each other.
For example, and referring to FIG. 1, in one embodiment, a first
pair of rollers 106 can be angled or twisted to laterally spread
the front and rear body panel webs 76, 78 a first amount before
they are shifted in the longitudinal machine direction. A second
pair of rollers 108 can be angled or twisted to laterally spread
the front and rear body panel webs 76, 78 a second amount after
they are shifted in the longitudinal machine direction. Of course,
it should be understood that the front and rear body panels can be
first shifted in the longitudinal machine direction the desired
amount and then separated in the lateral cross direction the entire
desired amount, or they can also be first separated in the lateral
cross direction the entire desired amount and then shifted in the
longitudinal machine direction. In another embodiment, the portions
of the lobes or peaks of the body panels overlap each other.
After the body panel webs 76, 78 are aligned and separated,
regardless of the order thereof, a plurality of crotch members 50,
for example absorbent inserts, are positioned in the lateral cross
direction so as to bridge the gaps 88 between the body panel webs
76, 78 at successive peaks 54, 154 or lobes 16, 24 where the
maximum rises of the body panel webs are aligned at the centerline
of the absorbent garment. It should be understood that the term
"gap" as used herein includes a "zero" distance between the
respective cut edges, wherein the cut edges abut but do not
overlap. The crotch members 50 are secured to the body panel webs
76, 78 as explained above. It should be understood that the crotch
members 50 are secured in one embodiment to a bodyside surface 90,
92 of the body panel webs 76, 78, although they can also be secured
to the garment side thereof as explained above with respect to
FIGS. 9-12. In one embodiment, the crotch members, for example the
absorbent inserts, are assembled offline and are then applied to
the front and rear body panel webs 76, 78 as those webs are carried
by a construction drum 110.
As shown in FIG. 1, the crotch member is preferably rotated using
an offset cam action rotator 112. The rotator includes a plurality
of transfer segments 126, which can have a vacuum applied thereto,
that engage the crotch member 50. Coupler arms 127 connect the
transfer segments and a drive ring. The coupler arm 127 includes a
cam end having a cam follower that follows the profile of a cam
mechanism. The profile of the cam mechanism can be readily changed
to change the desired speed output and pitch of the crotch member.
In one preferred embodiment, the rotator is configured to
accelerate the crotch member. If the successive crotch members 50
are separated by a perforation, the transfer segment 126 breaks the
perforation as it engages one crotch member and moves away from the
next crotch member, which is engaged by a next transfer segment
126. The rotator rotates the end portion of the transfer segment,
preferably approximately 90 degrees, about a radial axis, such that
the crotch member is oriented in the machine direction as described
above as the transfer segments are rotated about a horizontal axis
128. Alternatively, the landing material and fastener material are
cut and separated by the transfer segments. The rotator, and the
method for the use thereof, is further disclosed in U.S. Pat. Nos.
5,761,478, 5,759,340, and 6,139,004, and U.S. patent application
Ser. No. 10/038,766, entitled "Apparatus For Applying Discrete
Parts to A Moving Web," filed Jan. 2, 2002, all of which are
assigned to Kimberly-Clark Worldwide, Inc., the Assignee of the
present application, and the entire disclosures of all of which are
hereby incorporated herein by reference. Alternatively, the
subassembly can be rotated using a revolving transfer roll as shown
and described in U.S. Pat. No. 4,608,115, which is assigned to
Kimberly-Clark Worldwide, Inc., the Assignee of the present
application, and which is hereby incorporated herein by reference
in its entirety.
Referring to FIGS. 1 and 4, after the crotch members 50 are secured
to the body panel webs 76, 78 across the gap 88, the assembly is
conveyed on a conveyor 114 to a helical folder 116, wherein the
undergarments, and in particular the crotch members, are
successively folded such that the front and rear body panel webs
76, 78 are positioned in an overlapping, or overlying relationship,
preferably with the outer edges 80, 82 aligned. In various
alternative embodiments, the body panel webs 76, 78 can be secured,
for example by bonding, along a lateral cross direction at the area
of minimum rise, or valleys 56, 156 to form the side seam 48. The
front and rear body panel webs 76, 78 are then cut along the
lateral cross direction along the seam 48 to form a plurality of
discrete disposable undergarments, each having a front and rear
body panel 4, 6. Alternatively, the front and rear body panel webs
76, 78 can be first cut at the area of minimum rise, or valleys 56,
156, and the crotch member 50 thereafter folded. Various
refastenable fastening members can be applied to the front and rear
body panels 4, 6 or front and rear body panel webs 76, 78 before or
after the various cutting and folding operations. In yet another
preferred embodiment, as explained above, the undergarment can be
configured with side seams which secure the front and rear body
panels, and refastenable fastening members, which bridge lines of
weakness formed in one or the other of the body panels.
The elastic elements 36 are preferably incorporated into the web 72
of body panel material prior to cutting the web 72 to form the
front and rear body panel webs 76, 78. If leg elastics are desired,
preferably they are integrated into the web 72 along a pattern that
will follow the cut edge 84, 86 on each of the front and rear body
panel webs 76, 78. Of course, it should be understood that the
elastics could be secured to the body panel webs after they are
formed by the die cutter, or other cutting operation. In addition,
the elastics can be non-continuous and intermittently spaced along
the longitudinal direction such that they are incorporated along
only the leg opening portions 18, 26 of the body panel webs and
body panels.
The pitch (P) of the undergarment can be easily and quickly
adjusted without the need to change over to new dies. The term
"pitch" as used herein means the distance between any two adjacent
things in series, and in particular between the valleys 56, 156 or
side edges 30, 32 of the finished undergarment. In particular, the
web 72 of body panel material is simply stretched or elongated
various predetermined amounts before it is cut to form the front
and rear body panel webs 76, 78. For example, the largest waist/hip
size is provided when the web 72 of body panel material is
introduced into the cutting operation, or die cutter, with no
elongation or stretch in the longitudinal machine direction. The
smallest waist/hip size is provided when the web 72 of body panel
material is elongated or stretched to its maximum capability, such
that after the cutting operation, the front and rear body panel
webs 76, 78 retract to form a garment having a smaller pitch (P)
between the valleys. In one preferred embodiment, the elongation of
the body panel material is between about 20% and about 400%, in a
more preferred embodiment the elongation is between about 50% and
about 300%, and in a most preferred embodiment the elongation is
between about 100% and about 200%. The final size or pitch of the
undergarment is also determined by the process and positioning of
the side seams, and the distance therebetween.
The rise (R) of the undergarment, measured between the outer edges
20, 28, also can be easily and quickly adjusted without the need to
change over to new dies. In particular, the front and rear body
panel webs are simply spaced apart in the lateral cross direction
varying amounts, preferably with the gap being less than the length
of the crotch member. For example, for a smaller garment having a
lesser rise, the front and rear body panel webs 76, 78 are spaced
closer together, with a smaller gap 88 or by overlapping the body
panels, than for a garment having a greater rise.
Preferably, the same crotch member 50 can be used in any of the
garments, regardless of the pitch and rise. In this way, the
overall simplicity and efficiency of the system and method is
greatly improved, and there is no need to maintain inserts of
different sizes in inventory, or to provide manufacturing
capabilities to produce different size inserts. Indeed, the
preferred embodiment of the method provides for a system of
manufacturing a three-piece disposable undergarment with minimal
waste, while providing flexibility to manufacture different size
garments at minimal cost.
In one use, the body panels 4, 6 are elongated, with the attendant
application of a tensile force. At the same time, the absorbent
insert, which includes in one embodiment an extensible top sheet
206 and a stretchable/elastic back sheet 208, stretches or
elongates with the body panels. The back sheet can be elongated in
one embodiment between about 20% and about 150%, in another
embodiment between about 40% and about 125% and in another
embodiment between about 50% and about 100%. Since, in one
embodiment, the retention portion 212 is free floating, or
alternatively is minimally attached to the stretchable top sheet
and the stretchable/elastic back sheet, e.g., along the
longitudinal center line, the retention portion 212 does not
restrict the elongation of the back sheet 208 and top sheet 206, or
the attached body panels 4, 6.
In another use, the folded configuration of the absorbent insert 50
in combination with the absorbent insert being attached to the
garment side of the body panels, allows for the absorbent insert to
expand outwardly as it is insulted by the user. This expansion is
effected without affecting the fit to the body of the user. In
addition, the lobes of the body panels 4, 6, which extend over
portions of the absorbent insert 50, provide a physical barrier
between the absorbent insert and the body of the user.
Although the present invention has been described with reference to
preferred embodiments, those skilled in the art will recognize that
changes may be made in form and detail without departing from the
spirit and scope of the invention. As such, it is intended that the
foregoing detailed description be regarded as illustrative rather
than limiting and that it is the appended claims, including all
equivalents thereof, which are intended to define the scope of the
invention.
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